Catalyst Apparatus

ABSTRACT

A catalyst apparatus includes a metal carrier body for containing catalyst and at least a expansion room. The metal carrier body is arranged between an upstream portion and a downstream portion of an exhaust passage, and includes a gas entrance for conducting exhaust gas into the metal carrier body from the upstream portion and a gas exit for conducting the exhaust gas in the metal carrier body to the downstream portion. The expansion room is arranged between the gas entrance and the gas exit to communicate with a gas passage between the gas entrance and the gas exit for conducting the exhaust gas to flow between an inside of the metal carrier body and the expansion room.

FIELD OF THE INVENTION

The invention relates to a catalyst apparatus for treating exhaust gas, especially to a catalyst carrier body arranged in an exhaust passage of an engine and the catalyst carrier body includes at least an expansion room between a gas entrance and a gas exit.

DESCRIPTION OF THE RELATED ART

To meet the increasingly strict emission standards of the exhaust gas, metal carrier bodies containing a catalyst are provided in exhaust passages of engines. The catalyst usually includes Pd, Pt, Rh and other heavy elements. Pd and Pt can catalyze to convert CO to CO₂ and HC to H₂O. Rh can catalyze to convert NOx of exhaust gas to N₂ and O₂. Thus the metal carrier body containing catalyst can treat exhaust gas to reduce influences of exhaust gas on the environment.

A typical metal carrier body usually includes a cylinder body and at least a honeycomb body for carrying the catalyst in the cylinder body. The honeycomb body is formed by winding a flat plate or a corrugated plate. The honeycomb body includes a plurality of through-holes corresponding to two end sides of the cylinder body. The exhaust passage includes an exhaust pipe and a muffler. The metal carrier body can be selectively arranged in the exhaust pipe, in the muffler or between the exhaust pipe and the muffler, so the exhaust gas can flow through the through-holes of the metal carrier body and the catalyst can improve the efficiency of treating the exhaust gas.

However, the through-holes of the metal carrier body are all straight, when the exhaust gas flows into the through-holes, it will rapidly flow out from the metal carrier body without any obstacle. Thus, the contact time of the exhaust gas and the catalyst is inadequate.

BRIEF SUMMARY

The invention is to provide a catalyst apparatus comprising a carrier body and capable of increasing the time of exhaust gas staying in the carrier body to enhance the efficiency of the catalyst treating the exhaust gas.

For the above purpose, one embodiment of the invention provides a catalyst apparatus. The catalyst apparatus includes a metal carrier body for containing catalyst, arranged between a upstream portion and a downstream portion of a exhaust passage, and comprising a gas entrance for conducting exhaust gas from the upstream portion into the metal carrier body and a gas exit for conducting the exhaust gas in the metal carrier body to the downstream portion; and at least an expansion room, arranged between the gas entrance and the gas exit to communicate with a gas passage between the gas entrance and the gas exit for conducting the exhaust gas to flow between the inside of the metal carrier body and the expansion room.

For the above purpose, another embodiment of the invention provides a catalyst apparatus. The catalyst apparatus includes a first cylinder member and a second cylinder member arranged between a upstream portion and a downstream portion of an exhaust passage, wherein the first cylinder member and the second cylinder member form a carrier body, which includes a gas entrance for conducting exhaust gas from the upstream portion into the metal carrier body and a gas exit for conducting the exhaust gas in the metal carrier body to the downstream portion. The catalyst apparatus further includes a first expansion room in the second cylinder member, communicated with the gas entrance through the carrier body to conduct the exhaust gas to flow between the carrier body and the first expansion room. The catalyst apparatus further includes a second expansion room in the first cylinder member, communicated with the gas exit through the carrier body to conduct the exhaust gas to flow among the second expansion room, the carrier body and the gas exit.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout.

FIG. 1 is a sectional view of the catalyst apparatus according to the first embodiment of the invention.

FIG. 2 is a sectional view of the catalyst apparatus according to the second embodiment of the invention.

FIG. 3 is an exploded view of the catalyst apparatus according to the third embodiment of the invention.

FIG. 4 is a sectional view of the catalyst apparatus according to the third embodiment of the invention.

FIG. 4 a is a sectional view of a first cylinder member according to the third embodiment of the invention.

FIG. 4 b is a sectional view of a second cylinder member according to the third embodiment of the invention.

FIG. 5 is a sectional view when the catalyst apparatus of FIG. 4 is in use.

FIG. 6 is another sectional view when the catalyst apparatus of FIG. 4 is in use.

FIG. 7 is a sectional view of a cylinder body of the invention.

FIG. 8 is another sectional view of a cylinder body of the invention.

DETAILED DESCRIPTION

FIG. 1 is a sectional view of a catalyst apparatus according to the first embodiment of the invention. The catalyst apparatus includes a metal carrier body 1 for carrying catalyst and at least an expansion room 3.

The metal carrier body 1 is provided in an exhaust passage 5 and between an upstream portion 51 and a downstream side 52. The metal carrier body 1 includes a gas entrance 21 for conducting exhaust gas into the metal carrier body 1 from the upstream portion 51 and a gas exit 22 for conducting exhaust gas out of the metal carrier body 1 to the downstream side 52.

The expansion room 3 is provided between the gas entrance 21 and the gas exit 22 to communicate with a gas passage between the gas entrance 21 and the gas exit 22. Thus the exhaust gas can flow between the metal carrier body 1 and the expansion room 3.

As a more detail embodiment, the invention is described in the following paragraphs.

The metal carrier body 1 includes a cylinder body 10 and at least a honeycomb body 2 in the cylinder body 10. The honeycomb body 2 is selectively formed by winding a flat plate 27 (shown in FIG. 7), winding a corrugated plate (shown in FIG. 3), or winding a flat plate 27 and a corrugated plate (shown in FIG. 8). The catalyst includes Pd, Pt, Rh and other heavy metal elements. The catalyst is arranged in the honeycomb body 2 or coated in the honeycomb body 2 and on the wall of the cylinder body 10. The gas entrance 21 and the gas exit 22 are spaced out from each other by the honeycomb body 2 and include a plurality of though-holes 41 and a plurality of though-holes 42 for conducting the exhaust gas respectively.

The gas entrance 21 and the gas exit 22 are provided in a tail portion 2b of the honeycomb body 2. The expansion room 3 connects to a head portion 2a of the honeycomb body 2. The exhaust passage 5 is formed in a muffler room 60 of a muffler 6. The upstream portion forms a forward gas-congregating room 62 between a gas inlet 61 of the muffler room 60 and the gas entrance 21. The downstream portion 52 forms a backward gas-congregating room 63 between the gas exit 22 and a gas outlet 64 of the muffler room 60.

A first clapboard 71, a second clapboard 72 and a third clapboard 73 are arranged in the muffler room 60. The first clapboard 71 is arranged to space out the forward gas-congregating room 62 and the backward gas-congregating room 63. The second clapboard 72 is arranged to space out the forward gas-congregating room 62 and the expansion room 3. The third clapboard 73 is arranged to space out the expansion room 3 and the backward gas-congregating room 63. The gas inlet 61 connects to an exhaust emission port of an engine and the gas outlet 64 connects to the atmosphere.

According to the embodiment, after generated by the engine, the exhaust gas flows to the gas entrance 21 through the gas inlet 61 of the muffler room 60 and the forward gas-congregating room 62. Then the exhaust gas flows though the through-holes 41 of the metal carrier body 1 and is treated by contacting with the catalyst carried in the metal carrier body 1. And then the exhaust gas flows into the expansion room 3 and congregates here. Sequentially, the exhaust gas flows though the through-holes 42 of the honeycomb body 2 and is treated again by contacting with the catalyst in the metal carrier body 1. Then the exhaust gas flows to the atmosphere though the gas exit 22, the backward gas-congregating room 63 and the gas outlet 64. The though holes 41 and 42 of the metal carrier body 1 are designed as curve gas passages and the expansion room 3 is arranged between the exhaust passage to decrease the flowing speed of the exhaust gas. Therefore, the contact time of the exhaust gas and the catalyst is increased and the efficiency of treating the exhaust gas is enhanced.

FIG. 2 is a sectional view of a catalyst apparatus according to the second embodiment of the invention. With difference to the first embodiment, the catalyst apparatus includes a first expansion room 31 and a second expansion room 32. The first expansion room 31 and the second expansion room 32 are arranged between a gas entrance 23 and a gas exit 24 of the metal carrier body 1 to communicate with a gas passage between the gas entrance 23 and the gas exit 24. Thus the exhaust gas can flow among the metal carrier body 1, the first expansion room 31 and the second expansion room 32. The gas entrance 23 and the second expansion room 32 are provided in a tail portion 2 b of the honeycomb body 2. The gas exit 24 and the first expansion room 32 are provided in a head portion 2 a of the honeycomb body 2. The first expansion room 31 communicates with the second expansion room 32 and the gas entrance 24. The second expansion room 32 communicates with the first expansion room 31 and the gas exit 23. A first clapboard 74, a second clapboard 75, a third clapboard 76 and a fourth clapboard 77 are provided in the muffler room 60. The first clapboard 74 is provided between a forward gas-congregating room 65 and the second expansion room 32. The second clapboard 75 is provided between the second expansion room 32 and a backward gas-congregating room 66. The third clapboard 76 is provided between the forward gas-congregating room 65 and the first expansion room 31. The fourth clapboard 77 is provided between the backward gas-congregating room 66 and the first expansion room 31. A board 8 having a plurality of air vents and a board 80 having a plurality air vents are provided in the first expansion room 31 and the second expansion room respectively. The two ends of the board 8 and the board 80 contact with the sidewall of the metal carrier body 1 and the inside wall of the muffler room 60. The other structure and component of the catalyst apparatus according to the second embodiment are the same with those of the catalyst apparatus according to the first embodiment.

According to the second embodiment, the exhaust gas flows to the gas entrance 23 through the gas inlet 61 and forward gas-congregating room 65, and then flows through the through-holes of the honeycomb body 2 to be treated by contacting with the catalyst. Congregating in the first expansion room 31, the exhaust gas is buffed by the board 8. After flowing through air vents 81 of the board 8, the exhaust gas flows through the through-holes 44 of the honeycomb body 2 and is treated again by contacting with the catalyst. And then the exhaust gas flows to the second expansion room 32 and congregates there. In the second expansion room 32, the exhaust gas is buffed by the board 80. After passing through air vents 82 of the board 80, the exhaust gas flows through through-holes 45 of the honeycomb body 2 and is treated again by contacting with the catalyst. Sequentially, the exhaust gas flows to the atmosphere through a gas exit 20, the backward gas-congregating room 66 and the gas outlet 64.

FIG. 3 is an exploded assembly view of a catalyst apparatus according to the third embodiment of the invention. FIG. 4 is a sectional view of the catalyst apparatus according to the third embodiment. The cylinder body 10 includes a first cylinder member 11 and a second cylinder member 12. A honeycomb body 2 is provided between the first cylinder member 11 and the second cylinder member 12 and a honeycomb body 2. The first cylinder member 11, the second cylinder member 12 and the honeycomb body 2 form an metal carrier body 1 a. A gas entrance 25 is provided at the head portion 2 a of the honeycomb body 2. A gas exit 26 is provided at the tail portion 2 b of the honeycomb body 2. A first accommodating groove 13 (shown in FIG. 4 a) is formed in the first cylinder member 11. A second accommodating groove 14 (shown in FIG. 4 b) mating with the first accommodating groove 13 is formed in the second cylinder member 12 to accommodate the honeycomb body 2 with the first accommodating groove 13.

A first expansion room 33 is formed in the second cylinder member 12 and connected with the second accommodating groove 14. The first expansion room 33 communicates with the gas entrance 25 through the honeycomb body la to conduct the exhaust gas to flow between the honeycomb body la and the first expansion room 33. A second expansion room 34 is formed in the first cylinder member 11 and connected with the first accommodating groove 13. The second expansion room 34 communicates with the gas exit 26 and the first expansion room 33 through the honeycomb body 1 a to conduct the exhaust gas flowing between the honeycomb body 1 a and the first expansion room 33 to flow among the second expansion room 34, the carrier body 1 a and the gas exit 26.

The second cylinder member 12 includes a gas outlet 16 in accord with the gas exit 26. The first cylinder includes a gas inlet 15 in accord with the gas entrance 25. As shown in FIG. 3, FIG. 4 a and FIG. 4 b, a wedgy convex member 17 and a wedgy concave member 18 mating with the wedgy convex member 17 are respectively formed on the first cylinder member 11 and the second cylinder member 12.

As shown in FIG. 5, the exhaust passage 5 is formed in an exhaust pipe 9. The upstream portion 53 communicates with the gas exhaust of the engine and the gas entrance 25 is in a head portion 91 of the exhaust pipe 9. The downstream portion 54 communicates with the gas exit 26, a muffler and a tail portion 92 of the exhaust pipe 9. The other components and structure of the catalyst apparatus are the same with those of the catalyst apparatus according to the second embodiment.

As shown in FIG. 5, the exhaust gas flows to the gas entrance 25 through the head portion 91 of the exhaust pipe 9. Then the exhaust gas flows through the through-holes 43 of the honeycomb body 2. The exhaust gas is treated through contacting with the catalyst in the honeycomb body 2. And then the exhaust gas congregates in the first expansion room and flows through the through-holes 44. So the exhaust gas is treated again by contacting with the catalyst in the honeycomb body 2. Sequentially, the exhaust congregates in the second expansion room 34 and flows to the atmosphere through the tail portion 92, the gas exit 26 and the muffler. The exhaust gas is treated by contacting with the catalyst when passing through the through-holes 45 of the carrier body 2.

FIG. 6 is a sectional view of the catalyst converter according to the fourth embodiment of the invention. The exhaust passage 5 of the metal carrier body 1 a is formed in a muffler room 60 of a muffler 6 b. At least one clapboard 7 is provided in the muffler room 60 b to space an upstream portion 55 and a downstream 56. The metal carrier body la passes through the clapboard 7. The upstream portion 55 is a forward gas-congregating room 62 b between a gas inlet 61 b of the muffler room 60 b. The downstream portion 56 is a backward gas-congregating room 63 b between a gas exit 26 of the metal carrier body 1 a and a gas outlet 64 b of the muffler room 60. The gas inlet 61 b communicates with the gas exhaust port of an engine. The gas outlet 64 b communicates with the atmosphere. The other components and structure of the catalyst apparatus are the same with those of the catalyst apparatus according to the third embodiment.

The above description is given by way of example, and not limitation. Given the above disclosure body, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including configurations ways of the recessed portions and materials and/or designs of the attaching structures. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. 

1. A catalyst apparatus, comprising: a metal carrier body for containing a catalyst, arranged between an upstream portion and a downstream portion of an exhaust passage, and comprising a gas entrance for conducting exhaust gas into the metal carrier body from the upstream portion and a gas exit for conducting the exhaust gas to the downstream portion from the metal carrier body; and at least an expansion room, arranged between the gas entrance and the gas exit to communicate with a gas passage between the gas entrance and the gas exit for conducting the exhaust gas to flow between an inside of the metal carrier body and the expansion room.
 2. The catalyst apparatus of claim 1, wherein the metal carrier body comprises at least a cylinder body, and a honeycomb body arranged in the cylinder body, wherein the catalyst coats on the honeycomb body.
 3. The catalyst apparatus of claim 2, wherein the honeycomb body spaces the gas entrance and the gas exit, and the gas entrance and the gas exit respectively include a plurality of through-holes for conducting the exhaust gas.
 4. The catalyst apparatus of claim 2, wherein the honeycomb body is formed by winding a plat plate or a corrugated plate.
 5. The catalyst apparatus of claim 2, wherein the honeycomb body is formed by winding a plat plate and a corrugated plate.
 6. The catalyst apparatus of claim 1, wherein the exhaust passage is formed in a muffler room.
 7. The catalyst apparatus of claim 6, wherein the muffler room comprises a first clapboard arranged between the upstream portion and the downstream portion, a second clapboard arranged between the upstream portion and the expansion room, and a third clapboard arranged between the downstream portion and the expansion room.
 8. The catalyst apparatus of claim 6, wherein the expansion room comprises a first expansion room and a second expansion room, and the muffler room comprises a first clapboard arranged between the upstream portion and the second expansion room, a second clapboard arranged between the second expansion room and the downstream portion, a third clapboard arranged between the first expansion room and the upstream portion, and a fourth clapboard arranged between the first expansion room and the downstream portion.
 9. The catalyst apparatus of claim 7, wherein the upstream portion is a forward gas-congregating room between a gas inlet of the muffler room and the gas entrance, and the downstream portion is a backward gas-congregating room between a gas outlet of the muffler room and the gas exit.
 10. The catalyst apparatus of claim 7, wherein two boards with a lot of holes are arranged in the first expansion room and the second expansion room respectively, and spaces between an end surface of the metal carrier body and an inside wall of the muffler room.
 11. A catalyst apparatus, comprising: a first cylinder member and a second cylinder member arranged between an upstream portion and a downstream portion of an exhaust passage, wherein the first cylinder member and the second cylinder member form a carrier body, which comprises a gas entrance for conducting exhaust gas from the upstream portion into the metal carrier body, and a gas exit for conducting the exhaust gas in the metal carrier body to the downstream portion; a first expansion room in the second cylinder member, communicated with the gas entrance through the carrier body to conduct the exhaust gas to flow between the carrier body and the first expansion room; and a second expansion room in the first cylinder member, communicated with the gas exit through the carrier body to conduct the exhaust gas to flow among the second expansion room, the carrier body and the gas exit.
 12. The catalyst apparatus of claim 11 wherein the carrier body further comprises at least a honeycomb body arranged between the first cylinder body and the second cylinder body, wherein the catalyst coats on the honeycomb body.
 13. The catalyst apparatus of claim 12, wherein the honeycomb body spaces the gas entrance and the gas exit, and the gas entrance and the gas exit respectively include a plurality of through-holes for conducting the exhaust gas.
 14. The catalyst apparatus of claim 12, wherein the honeycomb body is formed by winding a plat plate or a corrugated plate.
 15. The catalyst apparatus of claim 12, wherein the honeycomb body is formed by winding a plat plate and a corrugated plate.
 16. The catalyst apparatus of claim 11, wherein the exhaust passage is formed in an exhaust pipe.
 17. The catalyst apparatus of claim 11, wherein the exhaust passage is formed in a muffler room.
 18. The catalyst apparatus of claim 11, wherein the muffler room comprises at least one clapboard formed therein to space the upstream portion and the downstream portion, and the carrier body passes through the clapboard. 